Shri Vaishnav Vidyapeeth Vishwavidyalaya, Indore

(2019-2020)

Industrial Training Report

On
“GRASIM INDUSTRIES LIMITED”
Submitted towards the partial fulfillment of Sixth semester
Bachelor of Engineering
in
Mechanical Engineering

Submitted To: Submitted By:

Mechanical Engineering Department Ashutosh Pandey

16010DMBME01049

Department of Mechanical Engineering

Shri Vaishnav Institute of Technology and Science, Indore

Shri Vaishnav Vidyapeeth Vishwavidyalaya, Indore

(Shri Vaishnav Institute of Technology and Science, Indore)

Page 1
 (2019-2020)
CERTIFICATE

This is to certify that ASHUTOSH PANDEY(1601DMBME01049) of Sixth

semester third year B.Tech. (Mechanical Engineering) has completed his
industrial training during academic year 2019-2020 as partial fulfillment of the
B.Tech (Mechanical Engineering) Course.

Prof. Santosh Patidar Dr. Shrikant Pandey

Industrial Training Coordinator HOD
Department of Mechanical Engineering Mechanical Department
SVITS, Indore

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 ACKNOWLEDGEMENT

First of all, thanks to my parent for giving encouragement, enthusiasm and invaluable
assistance to me. Without all this, I might not be able to complete this training properly.

I would like to thanks GRASIM INDUSTRIES that they provided me the opportunity to
undergo industrial training from their NAGDA-training centre. It is one of the leading staple
fiber making industry.

I would also like to thank my sincere gratitude Mr Rakesh Goyal(CS2 Acid Department
SFD) GRASIM INDUSTRIES, NAGDA. He guided me throughout training program so
that we can get full advantage of it.

Finally, I apologize all other unnamed who helped me in various ways to have a good
training.

I would also like to thank Dr. Shrikant Pandey (HOD Mechanical Department) and Prof.
Santosh Patidar(Industrial Training Coordinator) who provide me the opportunity to do
industrial trainining and this helped me a lot to learn practical things.

ASHUTOSH PANDEY
1601DMBME01049
B.Tech 6th SEM
(MechanicalEngineering)

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 ACKNOWLEDGEMENT

First of all, thanks to my parent for giving encouragement, enthusiasm and invaluable
assistance to me. Without all this, I might not be able to complete this training properly.

I would like to thanks GRASIM INDUSTRIES that they provided me the opportunity to
undergo industrial training from their NAGDA-training centre. It is one of the leading staple
fiber making industry.

I would also like to thank my sincere gratitude Mr Atul Khandelwal(Viscose Department

SFD) GRASIM INDUSTRIES, NAGDA. He guided me throughout training program so
that we can get full advantage of it.

Finally, I apologize all other unnamed who helped me in various ways to have a good
training.

I would also like to thank Dr. Shrikant Pandey (HOD Mechanical Department) and Prof.
Santosh Patidar(Industrial Training Coordinator) who provide me the opportunity to do
industrial trainining and this helped me a lot to learn practical things.

ASHUTOSH PANDEY
1601DMBME01049
B.Tech 6th SEM
(MechanicalEngineering)

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 CONTENTS
Page No.
Title Page 1
Certificate 2-3
Acknowledgment 4
Contents 5
List of figures 6

1. Introduction

1.1 Introduction 7

1.2 Industrial training objective 7

1.3 The important of industrial training to student 7

2. COMPANY BACKGROUND AND ORGANIZATION STRUCTURE

2.1 History 8

2.2 Organization chart 10

2.3 Company logo and product 11

2.4 Customer detail 11

2.5 Five years sales and profit graph 12

3. TECHNICAL CONTENTS

3.1 Safety 16

3.2 Quality parameters 17

4. Department and project detail 18

5. Conclusion 32

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 List of Figures

Figure Page
Description
No. No.

2.6 PROMOTERS 15

4.1 SITE LOCATION 19

4.2 VISCOSE PREPARATION 20

4.3 SPIN BATH PREPARATION 25

4.4 SPINNING OF VISCOSE SOLUTION 26

4.5 AFTER TREATMENT OF FIBRE 28

4.6 SULPHURIC ACID PLANT 30

4.7 CARBON DISULPHIDE (CS2) PLANT 31

4.8 PROCESS CHART 32

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1. INTRODUCTION

1.1 GRASIM :- AN INTRODUCTION

Grasim industries were incorporated on incorporated on August 25, 1947 . Having started
as a small textile manufacturer, the company is now an industrial conglomerate under the
chairmanship of Shri Kumar Mangalam Birla. Since its inception , Grasim has always
moved in line with India’s economic aspirations and has repeatedly scored success in all its
industrial ventures. Starting as a textiles manufacturer in 1948, today Grasim’s businesses
comprise viscose staple fiber (VSF), cement, chemicals and textiles. Its core businesses are
VSF and cement, which contribute to over 90 per cent of its revenues and operating profits.
The Aditya Birla Group is the world’s largest producer of VSF, commanding a 24 per cent
global market share. It is also the second largest producer of caustic soda (which is used in
the production of VSF) in India. Grasim Industries Limited is an Indian manufacturing
company based in Mumbai, Maharashtra. Grasim Industries was ranked 154th in a list of the
world’s best regarded firms compiled by Forbes. It was started in 1948 as a textile
manufacturer. Since then Grasim has diversified into Viscose Staple Fiber (VSF),
cement, sponge iron, chemicals and Diversified Financial Services (NBFC, Asset
Management and Life Insurance).
The company is a subsidiary of Aditya Birla Group, which operates over 40 companies in
12 countries on four continents. Grasim is the world's largest producer of viscose rayon fiber
with about 24% market share.Textile and related products contributes to 15% of the group
turnover.

1.2 INDUSTRIAL TRAINING OBJECTIVE

The main objective of Industrial Training is to expose to actual working environment and
enhance knowledge and skill.
It is also to help the students about the safety practices and regulations inside the industry
and to instill the spirit of teamwork and good relationship between students and employees.
Enhance students’ familiarity with the world of work and enable them to reflect
constructively in issues related to work.
Assist students to evaluate and understand how to work experience relates their personal or
career and future professional development.
Develop employability skills, intellectual skilss, core of key skills, personal attributes and
knowledge about how organizations work.
The purpose of this program is to instill the good qualities of integrity, responsibility and
self confidence.
1.3Importance of industrial training to students
Industrial training, where a student undertakes a period of training with an organization
usually during a semester break, act as an important part in preparing the student for a
professional career. With the active involved preparationthe student learns about the
industrial demands, skill set and work ethics. Industrial training is requires to overcome the
hurdles in the academic curriculum and in the industry. This will help the students create
and develop specific skills and competencies they require to become operable.This has been

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a practice in majority of the Western nations. So when they pass out from their college, at
the same time joining the company, they just have to learn the process followed in the
company. It gives an opportunity for graduates to apply theoretical knowledge gained in the
classroom with practical application of knowledge required to perform a task.
Additionally, taking part in internship programs permits the staffs of an organisation to
create leadership and monitoring skills, create presentation for the company, bring new
points of view and new thoughts into the work environment. t is also a helpful pathway for
the organization to select human assets as some assimilate trainees into their workforce after
they graduate.
Industrial Training is the important strategy to expose students to real work life situations
and to equip them with the necessary skills that intensify their job acumen. Industrial
training program or training related program can be continuously improved through
formal review and evaluation of its outcome.
A key element in an engineering curriculum is an exposure to the professional engineering
practice sought through industrial training. Industrial training has traditionally been weighed
as a potent grooming of the professional career of a fresh engineering graduate and it is the
common method of the harvesting skilled engineers. A well structured industrial training
program as a part of curricula has been recommended, But it is not made compulsory. In
addition to this, other structured industrial projects within the engineering curriculum are
required to strengthen the practical skills of the students.

2. COMPANY BACKGROUND AND ORGANIZATION

STRUCTURE

2.1HISTORY AND MILESTONE

Grasim Industries was established in 1947 and it started its Viscose Staple Fiber (VSF)
production in 1954 at Nagda in Madhya Pradesh [1]. Before the town was
industrialised, Nagda used to be mostly agricultural land. In 1952, GrasimIndustriesacquired
land for the construction of the viscose plant. Grasim is the largest exporter of Viscose
StapleFiber in the country, with exports to over 50 countries. Grasim is headquartered
in Nagda, Madhya Pradesh and also has a plant at Kharach (Kosamba, Gujarat)
and Harihar, Davangere in the state of Karnataka.
Indo-Thai Synthetics Company Ltd was incorporated in 1969 in Thailand, started operations
in 1970, this was Aditya Birla Group's first foray into international venture. Aditya Birla
Group incorporated P.T. Elegant Textiles in 1973 in Indonesia. Thai Rayon incorporated in
1974, this was the second company in Thailand, operating in Viscose Rayon Staple Fiber.
Century Textiles Co. Ltd. is taken over by Aditya Birla Group in 1974; this company is a
weaving and dyeing plant manufacturing and exporting variety of synthetic fabrics. PT
Sunrise Bumi Textiles incorporated in 1979, it produces yarn exported over 30 countries in
6 continents. P.T Indo Bharat Rayon incorporated in 1980 produces Viscose Staple Fiber in
Indonesia. Thai Polyphosphates and Chemicals was started in 1984 in Thailand to produce
Sodium Phosphates, and has merged with Thai Epoxy and Allied Products Company
Limited (1992), Thai Sulphites and Chemicals Company Limited (1995) to form Aditya
Birla Chemicals Ltd. This company supplies to sectorssuch as food, textiles, electrical and

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electronics, composites, leather, plastics and automobiles. PT Indo Liberty Textiles was
incorporated in 1995 to manufacture synthetic spun yarn.
In late 1990s and later, the focus was the textile business following the end of Multi-Fiber
Arrangement (MFA).
AV Cell Inc., a joint venture between Aditya Birla Group and Tembec, Canada, established
operations in 1998 to produce softwood and hardwood pulp for the purpose of internal
consumption among different units of the Group.
Together, Grasim Industries Ltd. and Tembec, Canada acquired AV Nackawic Inc., which
produces dissolving pulp. Grasim Industries Ltd. supplies Viscose Staple Fiber (VSP). The
Aditya Birla Group's VSF manufacturing plants are in Thailand, Indonesia, India and China.
The Group's VSF business operates through its three companies – Grasim Industries in
India, Thai Rayon Corporation in Thailand and Indo Bharat Rayon in Indonesia, which also
oversees its Chinese operations at Birla Jingwei Fibers, China.
In 2003, its Chemical Division was awarded the "Best of all" Rajiv Gandhi National Quality
Award.
1950– Production of fabrics at Gwalior with imported man–made rayon.
1954 – VSF production commences at Nagda (Madhya Pradesh).
1962 – Inception of Engineering Division for plant and machinery for VSF.
1963 – Composite textile mill at Bhiwani (Haryana).
1968 – Rayon production commences at Mavoor, Kerala.
1972 – VSF and Pulp plant at Harihar (Karnataka) based on in–house engineering and
know–how. Nagda commences production of rayon grade caustic soda ? for VSF
production.
1977 – Grasim's third rayon plant at Harihar, Karnataka goes into production.
1985 – Vikram Cement. Grasim's first cement plant goes on stream at Jawad (Madhya
Pradesh).
1987 – Vikram Cement's second production line is commissioned.
1991 – A third production line is added at Vikram Cement.
1992 – Grasim sets up Birla International Marketing Corporation (BIMC), a merchant
exporter.
1993 – Vikram Ispat, India's third largest gas–based sponge iron plant is commissioned.
Birla Consultancy & Software Services is set up, to provide IT consulting services and for
software development.
1995–Grasim commissions two Greenfield cement plants. Grasim Cement at Rawan
(Chattisgarh) and Aditya Cement at Shambhupura (Rajasthan). Vikram Woollens, spinning
unit at Malanpur (Madhya Pradesh) set up.
1996 – The first phase of Grasim's fourth VSF plant is commissioned at Kharach (Gujarat).
1999 – Grasim's viscose staple fiber (VSF) and rayon grade pulp units at Mavoor are closed
down owing to lack of raw material.
2000 – The Lawson Competency Centre is set up as a division of Birla Consultancy &
Software Services, the software arm of Grasim, following a tie up with Lawson Software
(USA), among Fortune's top five private software companies.
2001 – Four Ready–Mix Concrete plants commissioned with an aggregate capacity of one
million cubic meters.
2002 – VSF Research & Application Centre set up at Kharach in Gujarat.
2007 – Eighteen ready–mix concrete plants commissioned.
2009 – Grasim hives off its sponge iron business by way of slump sale

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Grasim commissions a greenfield cement plant at Kotputli (Rajasthan).Vikram Cement and
Aditya Cement win the Federation of Indian Mineral and Industries' 'Social Awareness
Award for the year 2008–09'.
Grasim's plants Vikram Cement (Khor, Madhya Pradesh) and Aditya Cement (Sambhupura,
Rajasthan), have won the TERI (The Energy and Resources Institute) CSR Award for their
sterling work in 37 villages among 12,550 families in the area of healthcare.
Mr. Ratan Shah, the Group Executive President and Chief Marketing Officer, Cement and
Mr. R. M. Gupta, Sr. Executive President, Vikram Cement and Aditya Cement, received the
Award at the hands of the honourable President of India, Mrs. Pratibha Patil on 5 June at
Vigyan Bhavan, New Delhi.
2010 – Consolidation of the cement business under UltraTech Cement Limited
2011 – Acquired DomsjoFabriker AB (Domsjo), Sweden, in a joint venture with Group
Companies
2012 – Acquired assets of Terrace Bay, a paper grade mill, in a JV with Group company
Thai Rayon, in July 2012

2.2 ORGANISATION CHART

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 2.3 COMPANY LOGO

Products and services offered by the company:

 Viscose staple fiber (VSF)

 Grey cement
 White cement
 Fertilizers
 Chemicals
 Mining
 Fatty Alcohol/Fatty Acids
 Insulators
 Software
 BPO
 Finance and Insurance
 Retail
 Sponge iron and
 Textiles.

2.4 CUSTOMER DETAILS

Aditya Birla Capital Limited (ABCL) is one of the largest financial services players in
India.

Formerly known as Aditya Birla Financial Services Limited, ABCL is the holding
company of all the financial services businesses of the Aditya Birla Group. With a
strong presence across the life insurance, asset management, private equity,
corporate lending, structured finance, project finance, general insurance broking,
wealth management, equity, currency and commodity broking, online personal
finance management, housing finance, pension fund management, health insurance
and asset reconstruction business, ABCL is committed to serving the end-to-end
financial services needs of its retail and corporate customers under the unified
brand — Aditya Birla Capital.

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 Anchored by more than 16,000 employees, ABCL has a nationwide reach and more
than 2,00,000 agents / channel partners. Aditya Birla Capital manages, through its
subsidiaries and joint ventures, aggregate assets worth Rs.3057 billion and has a
lending book of Rs.536 billion as of 30th June, 2018, placing it among the top 5
private diversified NBFCs in India (Source: CRISIL), the 3rd largest assets
management company in India by domestic AAUM as published by AMFI and as
one of the Top 5 Fund Managers in India (excl. LIC).

Aditya Birla Capital is a part of the Aditya Birla Group, a US$ 44.3 billion Indian
multinational, in the league of Fortune 500. Anchored by an extraordinary force of
over 120,000 employees, belonging to 42 nationalities, the Aditya Birla Group
operates in 35 countries across the globe.

Aditya Birla Capital Limited is the holding company of all the following
financial services businesses:
 Aditya Birla Finance Limited
 Aditya Birla Health Insurance Limited
 Aditya Birla Housing Finance Limited
 Aditya Birla Insurance Brokers Limited
 Aditya Birla Money
 Aditya Birla Myuniverse Limited
 Aditya Birla PE Advisors Limited
 Aditya Birla Sun Life Asset Management Company
 Aditya Birla Sun Life Insurance
 Aditya Birla Sun Life Mutual Fund
 Aditya Birla Sun Life Pension Management Limited
 Aditya Birla Asset Reconstruction Company Limited

2.5FIVE YEAR SALES AND PROFIT GRAPH

Mar'18 Mar'17 Mar'16 Mar'15 Mar'14

12Months 12Months 12Months 12Months 12Months

INCOME:

Sales Turnover 16034.71 11252.95 9785.92 6899.39 6100.07

Excise Duty 246.24 907.30 806.32 566.81 496.57

NET SALES 15788.47 10345.65 8979.60 6332.58 5603.50

Other Income 0 0 0 0 0

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TOTAL INCOME 16249.83 10819.58 9261.37 6680.65 5988.29

EXPENDITURE:

Manufacturing Expenses 2771.23 1772.67 1745.65 1239.83 888.67

Material Consumed 7862.87 5144.15 4717.38 3762.14 3181.81

Personal Expenses 1142.72 678.00 610.22 482.25 378.80

Selling Expenses 60.25 25.15 15.37 .00 .00

Administrative Expenses 871.22 570.91 312.28 183.39 292.89

Expenses Capitalised .00 .00 .00 .00 .00

Provisions Made .00 .00 .00 .00 .00

TOTAL EXPENDITURE 12708.29 8190.88 7400.90 5667.61 4742.17

Operating Profit 3080.18 2154.77 1578.70 664.97 861.33

EBITDA 3541.54 2628.70 1860.47 1013.04 1246.12

Depreciation 627.66 446.14 447.14 262.55 219.61

Other Write-offs .00 .00 .00 .00 .00

EBIT 2913.88 2182.56 1413.33 750.49 1026.51

Interest 128.13 57.62 147.40 39.33 41.52

EBT 2785.75 2124.94 1265.93 711.16 984.99

Taxes 744.48 564.94 283.47 155.02 89.00

Profit and Loss for the Year 2041.27 1560.00 982.46 556.14 895.99

Non Recurring Items -285.48 -8.61 -29.19 -26.24 .00

Other Non Cash Adjustments .00 .00 .00 .00 .00

Other Adjustments 12.87 8.61 .00 .00 .00

REPORTED PAT 1768.66 1560.00 953.27 529.90 895.99

KEY ITEMS

Preference Dividend .00 .00 .00 .00 .00

Equity Dividend .00 .00 199.22 168.74 185.36

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Equity Dividend (%) .00 .00 213.41 183.67 201.85

Shares in Issue (Lakhs) 6573.71 4668.37 933.46 918.52 918.27

EPS - Annualised (Rs) 26.91 33.42 102.12 57.69 97.57

Rs (in Crores)
.

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2.6 PROMOTERS :-

The founder of GRASIM was Shri Ghanshayam Das Birla and now the promoters are
Aditya Vikram Birla and Kumar Mangalam Birla.

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 3. TECHNICAL CONTENTS
3.1 SAFETY

Safety is a degree of protection from hazards,the condition or state of being safe ,freedom
from danger,exemption from hurt. It is the basic requirement of all industrial plants to make
zero accidents and hazards.
Safety policy :
“To develop safety consciousness and ensure that the employees are familiar with the
general and special practices followed in the plant during working.”
USE OF PPE’S :
PPE is equipment that will protect the user against health or safety risks at work. It can
include items such as safety helmets, gloves, eye protection, high-visibility clothing, safety
footwear and safety harnesses. It also includes respiratory protective equipment (RPE).
Making the workplace safe includes providing instructions, procedures, training and
supervision to encourage people to work safely and responsibly.
Even where engineering controls and safe systems of work have been applied, some hazards
might remain. These include injuries to:

 the lungs, eg from breathing in contaminated air

 the head and feet, eg from falling materials
 the eyes, eg from flying particles or splashes of corrosive liquids
 the skin, eg from contact with corrosive materials
 the body, eg from extremes of heat or cold

Eyes
Hazards
Chemical or metal splash, dust, projectiles, gas and vapour, radiation
Options
Safety spectacles, goggles, face screens, faceshields, visors
Head and neck
Hazards
Impact from falling or flying objects, risk of head bumping, hair getting tangled in
machinery, chemical drips or splash, climate or temperature

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3.2 Quality Parameters :-

During manufacture, the quality control (QC) of allergenic extracts presents a variety of
challenges. One important consideration is the expected variability that is inherent with
naturally derived source materials. Allergenic extracts exhibit a certain degree of lot-to-lot
variability that cannot be avoided. However, if the extract manufacturing steps are well
controlled this allows each supplier to deliver products that have a reasonable level
of batch consistency.

At present, quality monitoring of extracts is primarily accomplished by characterizing the

final product with various analytical methods. ALK has defined four quality parameters that
should be monitored throughout the manufacturing process. These include:

A ‘well-characterized’ approach to an extract quality assessment would require that all four

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parameters be evaluated. An effective quality monitoring program would then provide
additional information to the Allergy Specialist to support allergy diagnosis and treatment
decisions. ALK is pursuing this well-characterized approach for a number of extracts and
data are available to allergy clinics upon request.

3.2.1WATER QUALITY
Water quality testing is an important part of environmental monitoring. When water quality
is poor, it affects not only aquatic life but the surrounding ecosystem as well.

These sections detail all of the parameters that affect the quality of water in the
environment. These properties can be physical, chemical or biological factors. Physical
properties of water quality include temperature and turbidity. Chemical characteristics
involve parameters such as pH and dissolved oxygen. Biological indicators of water quality
include algae and phytoplankton. These parameters are relevant not only to surface water
studies of the ocean, lakes and rivers, but to groundwater and industrial processes as well.

Water quality monitoring can help researchers predict and learn from natural processes in
the environment and determine human impacts on an ecosystem. These measurement efforts
can also assist in restoration projects or ensure environmental standards are being met.

4. DEPARTMENT AND PROJECT DETAILS

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4.1SITE LOCATION

The department in which I worked is VISCOSE DEPARTMENT where the process starts
of making fiber.

The viscose process dissolves pulp with aqueous sodium hydroxide in the presence
of carbon disulfide. This viscous solution bears the name viscose. The cellulose solution is
used to spin the viscose rayon fiber, which may also be called viscose. Viscose rayon fiber
is a soft fiber commonly used in dresses, linings, shirts, shorts, coats, jackets, and other
outerwear. It is also used in industrial yarns (tyre cord), upholstery and carpets, and in the
casting of cellophane.
Viscose production primarily consists of three stages, viz. conversion of initial cellulose of
wood
pulp into alkali-cellulose by the action of Sodium Hydroxide, aging of alkali-cellulose and
conversion of alkali-cellulose into Cellulose Xanthate & dissolving in dilute sodium
hydroxide to
produce viscose. Sufficient interval is allowed between mercerisation of pulp and
Xanthation of
alkali-cellulose for ageing, to shorten cellulose chain length. The xanthation reaction is
generally formulated as follows:
ROH + NaOH + CS2 ---------------> ROCS, SNa + H2O

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The viscose produced is filtered in three stages to remove undissolved particles and
impurities;
deaerated and is extruded under pressure through spinnerets, kept submerged in a
coagulating
bath where cellulose is regenerated as fine filaments.
Detailed description of manufacturing process of VSF is given as under:
The Process comprises of following stages:
1. Viscose Preparation
2. Spinning Bath Preparation
3. Spinning of Viscose Solution
4. After treatment of Fiber

4.2 Viscose Preparation

4.2.1 PULPER
At first a badge of 300 kg is made (AV CELL AND SAPPI) then pulp is transferred to
pulper through AUTO PULP CHARGING SYSTEM(APCS). For mercerization of Rayon
Grade Pulp, Pulpers are used. Rayon Grade Pulp (cellulose) isreacted with 18% Caustic
Soda Solution. Pulp are dumped in Slurry Mixer tanks fitted withhigh-speed agitators to
form slurry with caustic soda. Slurry thus obtained, are pumped to
a homogeniser tank with the help of Rotto Pump and thus this system has a coupling and
shaft connected in it .
4.2.2TWIN ROLLER PRESS
The slurry from homogenizer is continuously sent to Slurry Press, where excess
caustic soda is squeezed out and slurry is squeezed into blanket and slurry is converted in
the form of alkcell mat.Rollers revolve in opposite direction and one of the roller is movable
to maintain the thickness between rollers.The excessive caustic soda is removed from the
slurry and it is then
recycled and sent to the Caustic Soda Station for make-up and recycle. The squeezed
blanket or mat from
slurry presses enters into twin rolllers which breaks theslurry mat into small pieces and then
these small parts are then sent to a shredder which consists of three rollers and they have
pins like sharp tips which breaks the slurry pieces into powdered form and then it is sent to
WAGNER FILTER and then to the press lye tank and reused. The alkcell is then sent to
maturing drum.
4.2.3 AEGING/MATURING DRUM
The shredded alkali-cellulose is fed into a long 22 feet drum, slowly-rotating which has a
jacket at its outer part which contains water at a temperature (45-48 C).Aeging / maturing
or
Aeging Box to maintain desired temperature of alkali-cellulose to control ageing, which is
accomplished in 2.45 hours. The maturing drum takes 2.5minutes to take one round and it is
rotating with gear system in which a wheel is connected to a pinion and the drum is attached
to different rings. The girth gear is attached at the centre. The alkcell is rotating in the
maturing drum where warm water is making the alkcell dry and swell them. The impeller is
placed inside the drum. The drum is inclined at an angle of 7 degrees. In this drum process
of Depolymerization takes place.
i)TEMPERATURE :-The jacket at the outer part of the drum works as a heat exchanger
and the flow of water and alkcell is counter flow which increases the efficiency. The
efficiency of heat exchanger can be calculated by using Log Mean Temperature Difference
(LMTD).

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ii)PRESENCE OF CATALYST :- The function of catalyst is to increase the reaction. In
maturing drum MnSO4 acts as a positive catalyst which increase the rate of reaction.

4.2.4 COOLING DEVICE

A coolind device is used just after maturing drum to maintain the temperature of hot alkcell.
For this the alkcell is send through one pipe and another pipe is connected to a coolind
device and hence the alkcell came in contact with cool air and make the alkcell cool. The
temperature here maintained is 30 degrees which however, makes the quality of fiber good.
After that the alkcell gets cooled it is send to the hopper with the help of a blower. Blower is
set up like that motor is connected to a muff coupling and a shaft is connected to it and air is
blown through the blower and the alkcell is pneumatically sent to the hopper.

4.2.5 HOPPER
After passing from cooling device ,the alkcell is sent to the hopper where it is collected and
stored. Hopper is like a storage tank of huge capacity approx. 2600kg at a time. Hopper has
a mechanism that when a requirement of alkcell is got it is taken from the hopper and the
sononite valve is opened and the collected alkcell is passed to the simplex.

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4.2.6 SIMPLEX
The aged alkali-cellulose is made to react with Carbon-Disulphide under vacuum in
Xanthator for an approximate time of 50 minutes to produce Cellulose Xanthate, which is
later dissolved in chilled 3% Caustic Soda Solution. The entire process is accomplished in
wet
condition to avoid exposure of gases. From the Xanthator, discharging is done by remote
control without any manual handling.
In Simplex the alkcell is taken into the process and 265 kg of Carbon Disulphide is
addedand vacuum upto 25 inch is taken and then CS2 is added. The mixture is mixed and
dissolve in it for 45 minutes at low speed of ratio of shaft and impeller at 24:1 and then after
at low speed for 5 minutes and after 61000 litres of lye is added and then it is mixed foe 20
minutes. The setup is like this that gear is connnecgted to coupling and shaft and this is how
the setup works.
The xanthator is a large capacity vessel with jacket and two-speed agitator of special design.
After charging alkali cellulose, it is tightly covered and vacuum of 600-650 mm Hg is
applied.

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The agitator is run at slow speed and the required quantity of carbon disulphide is admitted
through a spray-pipe. With instant vaporisation of carbon-disulphide, the vacuum drops but
with the progress of the reaction in Xanthation, the vacuum is regained. At this stage, the
charge of dilute caustic soda is taken into the xanthator. The xanthator is then exhausted
and xanthate slurry is dropped into a dissolver.
The dissolvers are energy-efficient equipments with impeller of special design. The
dissolver
is cooled by circulating chilled water through its jacket for low temperature dissolving. The
mixture is now orange in colour and approx. all the balls of alkcell and thus gets converted
into liquid. After this the liquid is sent to the dissolver. Simplex is a very hazardous section
in making of viscous as the chaces of having blast due to CS2 are very high. The exhaust
gases are removed through the exhaust.

4.2.7 DISSOLVER
In dissolver, Xanthate slurry is thoroughly dissolved through coarse and fine disintegrators
for about 3 hrs. to dissolve cellulose xanthate into viscose solution.
The dissolvers are energy-efficient equipments with impeller of special design. The
dissolver
is cooled by circulating chilled water through its jacket for low temperature dissolving.
In the dissolver section the mixture is feed into the drum like feeder which has wire framed
net in which the mixture is passing again and again so that the balls will broke and mix with
mixture and the setup of the dissolver tank is connected with pump , coupling and shaft and
it is rotating at two speeds at 720 and 1440 RPM’s and the process is carried out in four
times as first it is rotated at higher speed for 15 minutes then at low speed for 18 minutes
then again at lower speed for 25 minutes and then at higher speed for 30 minutes. Here at

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this stage the alkcell is finally converted in liquid form.

4.2.8 RIPENING,FILTRATION
Ripening section is the coolest section as the temperature maintained is at very low and to
maintain the filtration unit at constant.
This system consists of blenders, receiving tanks, first stage filtration, first intermediate
tank, second stage filtration, second intermediate tank, flash deaerator, third stage
filtration and spinning tanks.
Viscose produced in Dissolvers is ripened in ripening room for about 12 hrs. under
controlled
temperature conditions. Viscose solution is pumped into series of tanks and passed through
3 stages of filters for removing undissolved impurities. Viscose solution is also passed
through high vacuum flash de-aerators for removing entrapped air. The filtered and
deaerated
viscose is collected in spinning tanks. The spinning tank is a closed tank and viscose
is pumped to spinning machine from the spinning tank.

The process as starts is that the G.C.F. (GRASIM CONTINUOUS FILTER) which has a
cylindrical hollow ring is put inside it and a wire filter is placed over it and then the process
starts. As from G.C.F. the viscous is entered and the pressure in pressure vessel rises and the
piston starts moving inside the G.C.F. and the liquid that is able to flow through that wire is
sent to another filter and the part that us not filtered came out of the wire filter and the
filter’s size is in micrometers. As from G.C.F. it is sent to second filterate unit and after that

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it is sent to first intermediate tank and the unfiltered liquid is sent to receiving tank.
Similarly after that it is sent to second intermediate tank where the more small particles are
filtered and then it is passed through flash deaerator where the air is taken out and the
vacuum is created and then it is sent to third intermediate tank where it get its final filter. At
this stage finally the viscous is prepared and then it is sent to spinning department.

4.3 SPIN BATH PREPARATION:-

A coagulating bath (Spin bath) used for regeneration of cellulose in viscose in the form of
fiber is composed of Sulphuric Acid, Sodium Sulphate, Zinc Sulphate, Alum and Water.
During regeneration, the alkali present in the viscose reacts with sulphuric acid to form
sodium sulphate

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Expansion of Viscose Staple Fiber (1,27,750 to 2,33,600 TPA), Sulphuric Acid(1,46,000 to
2,19,000 TPA), Carbon-Disulphide (21,600 to 37,295TPA) and Captive Power Plant
andwater. Hence, there is a continuous depletion of Sulphuric Acid and build-up of Sodium
Sulphate in the spin bath.

The preparation of spin bath is carried out in a series of equipment like circulation tanks,
spin bath filters, evaporators, and crystallizer and, rotary vacuum filters. The dilution of
spin bath occurs due to large water content in viscose and water generation by the reaction
of caustic soda and sulphuric acid in spin bath. A continuous stream of spin bath is drawn
from the system for water evaporation and crystallisation of Sodium Sulphate. Fresh 98%
concentrated sulphuric acid and Zinc are added to the system to make up for their dilution.
Water evaporation is carried out in a series of in MultiEffect Evaporators (MEE). The
removal of sodium sulphate from the system is brought about by the crystallisation in the
form of glauber salt, and then converted in to anhydrous sodium sulphate. Spin bath is
purified by passing through pressure filters and heaters to acquire desired temperature. It is
continuously fed to Spinning Dept. from gravity tanks. Anhydrous Sodium Sulphate
Manufacturing Glauber salt crystals are melted in their own water of crystallization and the
water is evaporated from the resultant liquor in 3 stage Anhydrous Evaporators, which is
subsequently thickened in settler and filtered to remove sodium sulphate. Further, removal
of water is accomplished in a Drumtype dryer and almost bone-dry salt is bagged for
sending it to Customers. The hot air exhausted from the salt dryer is passed through a
cyclone separator, water scrubber for complete removal of carryover of salt.

4.4 SPINNING OF VISCOSE SOLUTION :-

The filtered and de-aerated viscose is sent to Staple Fiber Extrusion Machines through
spinnerets. A coagulating bath (Spin bath) consisting of Sulphuric Acid, Sodium Sulphate
and Zinc Sulphate is used for regeneration of cellulose in viscose. Viscose is forced under
pressure through very fine holes contained in cup shape nozzles (Spinnerets) immersed in
coagulating / regenerating bath (called Spin bath). Emerging viscose filaments are
coagulated and regenerated into fine filaments, accompanied by formation of Sodium
Sulphate. The machine produces fiber of various denier and length. The regenerated fiber is
subjected to stretch during entire generation process, which the molecules along the length
of the fiber to impart the strength. During this stage as well carbon disulphide is recovered
through series of condensers and the liquid CS2 is collected in tanks, purified and reused in

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xanthation process. This stage also maintains very efficient recirculation system and
exhaust system.

In spinning department, the spin bath and the viscose mix with each other in the spin bath
trough and threads of fiber starts forming with the mixing of them and then threads are put
on godets and then through these godets fiber starts to move and water is used to wash this
now it move towards STRETCHED ROLLERS where fiber stretched to its maximum
capacity and then it move towards TRIO ROLLERS and they carry the fiber and send it to
the cutters. The mechanism behind TRIO ROLLERS works as motor connected with them
which moves these rollers one in clockwise and one in anti-clockwise direction. After
moving to cutter the fiber comes under AFTER TREATMENT DEPARTMENT.

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4.5 AFTER TREATMENT OF FIBER

4.5.1WASHING ZONES :-

Fiber is washed, de-sulphurized and bleached to remove undesirable sulphur and colour.
From CS2 recovery trough the fiber goes to washing zones and CS2 is collected separately.
At different washing zones rollers are placed and fiber is pressed in between them and at
proper intervals water is used for cleaning. CL90 is a chemical used for placing the colour
permanently in the fiber and after that it is passed through hydraulic jacks which are placed
below the squeeze rollers to make the wetness out from the fiber.

4.5.2 DRYER :-

It is then soft finished, and dried in Drum type fiber dryers. Drum dryers are placed inside
the channels and run by chain drives. For drying fiber different temperature are placed at
different dryer a channel of dryers is set up and drying process is going like this.

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4.5.3 BALING PRESS :-

Dried fiber is passed through rollers to make fully dried and then passed through section in
which booster fan is placed which sends fiber upwards pneumatically where air make the
fiber free and then it sent to baling press for packing. The fiber fleece from the carbon-
disulphide recovery system is sent to latest technology after treatment machine for
purification. This machine has number of washing and treatment zones. The fiber fleece
passes through these zones where it gets de-sulphurised, washed and bleached to remove
undesirable sulphur and colour. To avoid wastage and to maintain proper concentration of
treatment liquors, a very efficient recirculation system with squeezing arrangement is
designed. An efficient exhaust system is also provided on the machine. Fiber is then soft
finished, and dried in Drum type fiber dryers. Dried fiber is opened and sent to baling press
for packing.

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4.6 SULPHURIC ACID PLANT

The sulphuric acid plant is based on DCDA technology with high heat-recovery and gas
scrubbing system for better pollution control. 98% Sulphuric Acid is manufactured from
rock sulphur by contact process. The powdered sulphur is melted in sulphur melting pits. It
is purified in a series of setting chambers and leaf type filters.

The cleaned sulphur is burnt with air to yield sulphur dioxide. This is accomplished in a
furnace, which is lined with suitable refractory. The temperature of gases leaving furnace is
around 1000°C. These gases are cooled to about 430°C in a waste heat boiler where steam
is generated. The cooled gases are first filtered in a hot gas filter before feeding to a five-
stage converter. The converter has Vanadium Pentoxide (V2O5) catalyst spread over
different beds. Sulphur dioxide and oxygen in air react together to form sulphur trioxide.
This reaction being exothermic in nature, the temperature of gas increases. It is brought
down to 420 °C before it is fed to subsequent stages. Gases after third stage of conversion,
which are sufficiently rich in sulphur trioxide, are fed to Absorber I for absorption of
sulphur trioxide.

The temperature of gases is brought down to 150 °C before their entry into Absorber – I.
The unabsorbed gases are reheated by the incoming gases in indirect heat exchangers and
fed to fourth stage of converter. The gases after the fifth stage are again cooled and fed to
Absorber – II. The unabsorbed gases comprising mainly inert, air, traces of sulphur dioxide,
sulphur trioxide and acid mist are discharged into atmosphere through scrubber. Air used in
the process is first dried in a drying tower.

98% acid is used for absorption for sulphur trioxide and air drying. The sulphuric acid thus
gets concentrated continuously. Soft water is added to maintain the concentration around
98%. There is considerable heat evolved during absorption of sulphur trioxide in Sulphuric
Acid and during dilution of sulphuric acid with water. Further heat is also taken-up by acid
due to sensible heat loss by gases. The sulphuric acid is continuously cooled to desired
temperature in heat exchangers. Acid circulation tanks and pumps are used for maintaining
the supply of requisite concentration of sulphuric acid to various towers. Product acid is
continuously drawn off.

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4.7 CARBON DISULPHIDE PLANT

Wood Charcoal is used as source of carbon and is calcined before use. Calcined Wood
Charcoal is received in the electric furnace batch wise through a cup and cone of
arrangement. Controlled quantity of molten sulphur is continuously fed into the electric
furnace.

Constant temperature around 900 to 1000 deg C is maintained by electric heating of

charcoal bed between the electrodes.

Vapours of CS2 along with hydrogen impurities like hydrogen sulphide and sulphur are
discharged from the electric furnace to sulphur separator and series of condensers. Crude
CS2 is collected under water in storage tanks and refined before it is sent to Viscose Section
for Xanthattion.

During the manufacturing of CS2 main pollutant is H2S which is scrubbed by alkali. Crude
CS2 received from storage is refined, in distillation columns, condensed and stored under
water. Crude CS2 is received in the first distillation column where is meets the vapours of
CS2 rising from evaporation chamber. Thereby after series of stripping CS2 from highly
volatile Hydrogen sulphide, CS2 vapours are condensed and partly recycled. Refined CS2 is
stored under water.

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4.8 PROCESS CHART

5.CONCLUSION
The industrial training that I had already gone through for 4 Weeks at GRASIM
INDUSTRIES is very interesting, instructive and somehow challenging for someone
that has zero-working experience. It gave me lots of benefit and positive changes that
enable me to enter the working environment. Through this training I was able to gain
new insights and more comprehensive understanding about the real industry working
condition and practice. The 4 weeks of training has provided me the opportunities to
develop and improve my soft and functional skills. All of this valuable experience
knowledge that I have gained were not only acquired through the direct involvement in
task given but also through other aspect of the training such as work observation,
interaction with the staffs and local people. I learned about pumps,couplings,shafts,etc.

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